Procedure

e-Con Number

PHR-PP-QC-GG-006
Welding Procedure

Operating environment: onshore

Intended for internal use PHR or other area as per guidance or permit

This document is the confidential property of PHR

Rev Date Description Developed Reviewed Approved

0 Sep 21 Issued For Implementation Team Rio Sirait Erwin Sianturi
Welding Procedure PHR-PP-QC-GG-006

Summary of Changes
Rev. xx Rev. xx Description Type of Change

Team Review:

- Nur Aditya Buana

- Andi Wirawan
- Adianto Silaban
- Muhamad Sidik
- Sofyan Yusuf

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Welding Procedure PHR-PP-QC-GG-006

Contents
1 GENERAL ......................................................................................................................................... 1
Scope ....................................................................................................................................... 1
References .............................................................................................................................. 1
Related Specification....................................................................................................... 1
Code and Standards ........................................................................................................ 1
Terminology ............................................................................................................................ 2
COMPANY ....................................................................................................................... 2
CONTRACTOR .................................................................................................................. 2
Vendor............................................................................................................................. 2
MIGAS ............................................................................................................................. 2
Conflicting Requirements........................................................................................................ 3
2 WPS DOCUMENT ............................................................................................................................ 3
3 WELDING PROCESS ......................................................................................................................... 3
4 VARIABLE ......................................................................................................................................... 3
Material ................................................................................................................................... 3
Base Metals ..................................................................................................................... 3
Filler Metals..................................................................................................................... 4
Position ................................................................................................................................... 6
Thermal Treatment ................................................................................................................. 7
Preheat and Interpass Temperature ............................................................................... 7
Post Weld Heat Treatment ............................................................................................. 7
5 FABRICATION .................................................................................................................................. 8
Surface Preparation ................................................................................................................ 8
Joint Requirement and Preparation........................................................................................ 8
Workmanship .......................................................................................................................... 9
6 INSPECTION AND TEST .................................................................................................................. 10
General .................................................................................................................................. 10
NDE (Nondestructive Examination) Requirements............................................................... 10
Visual Examination ........................................................................................................ 10
Liquid Penetrant Examination....................................................................................... 10
Magnetic Particle Examination ..................................................................................... 11
Ultrasonic Examination ................................................................................................. 11
Radiographic Examination ............................................................................................ 11
Mechanical Testing of Welding ............................................................................................. 11

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Welding Procedure PHR-PP-QC-GG-006

7 REJECTION ..................................................................................................................................... 12
8 WELDING REPAIRS ........................................................................................................................ 12

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Welding Procedure PHR-PP-QC-GG-006

1 GENERAL
Scope
This document specifies the minimum requirement and serves as a guidance of welding procedure
specification to determine that the weldment proposed to construct structure or equipment is capable
of providing the required properties for its intended application.
This document is applicable for piping shop/field fabrication, ASME pressure retaining components,
ASME non-pressure retaining components and carbon-steel structural components.

References
Related Specification
This document shall used for the related documents as mention below :
• PHR-PP-PI-PP-013 Pipe Welding & Weld Inspection
• PHR-PP-PI-PP-014 Field Welding & Weld Repair of Pipeline
• PHR-PP-QC-GG-003 Inspection and Test Plan at Shop
• PHR-PP-QC-GG-004 Inspection and Test Plan at Field
• PHR-PP-QC-GG-005 NDT Procedure
• PHR-PP-QC-GG-007 Welder Qualification and Certification

Code and Standards

Applicable code and standard are as follows:
1.2.2.1 ANSI (American National Standard National)
• ANSI B31.1 Power Piping
• ANSI B31.3 Process Piping
• ANSI Z49.1 Safety in Welding and Cutting

1.2.2.2 ASME Boiler and Pressure Vessel Code

• Section II Material Specifications, Part C
• Section V Non-Destructive Examination
• Section VIII Boiler and Pressure Vessels, Div. 1 and 2
• Section IX Welding and Brazing Qualifications

1.2.2.3 AWS (American Welding Society)

• A2.4 Symbol for Welding and Nondestructive Testing
• A3.0 Welding Terms and Definitions
• A4.2 Calibrating Magnetic Instruments to Measure Delta Ferrite
• A5.1 Specification for Carbon Steel, Covered Arc Welding Electrodes
• A5.4 Corrosion-Resisting Chromium and Chromium-Nickel Steel Covered Welding
Electrodes
• A5.5 Low-Alloy Steel Covered Arc Welding Electrodes
• A5.9 Corrosion-Resisting Chromium and Chromium-Nickel Steel Bare and Composite
Metal Cored and Standard Welding Electrodes and Welding Rods
• A5.11 Nickel and Nickel Alloy Covered Welding Electrodes
• A5.14 Nickel and Nickel Alloy Bare Welding Rods and Electrodes
• A5.17 Specification for Carbon Steel Filter Electrodes and Fluxes for Submerged Arc
Welding

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Welding Procedure PHR-PP-QC-GG-006

• A5.18 Specification for Carbon Steel Filter Metals for Gas Shielded Arc Welding.
• A5.20 Specification for Carbon Steel Electrodes for Flux-Cored Arc Welding
• A5.23 Low-Alloy Steel Electrodes and Fluxes for Submerged. Arc Welding
• A5.28 Low-Alloy Steel Filler Metals for Gas Shielded Arc Welding
• D1.1 Structural Welding Code-Steel, Section

API (American Petroleum Institute)

• Std 510Pressure Vessel Inspection Code
• Std 650Welded Steel Tanks for Oil Storage

ASTM (American Society for Testing and Materials)

• A 36 Structural Steel
• A 53 Grade B, Pipe, Steel, Black and Hot-Dipped, Zinc Coated Welded and Seamless
• A 500 Cold-Formed Welded and Seamless Carbon Steel Structural Tubing in Rounds and
Shapes
• A 501 Hot-Formed Welded and Seamless Carbon Steel Structural Tubing in Rounds and
Shapes
• A 516 Pressure Vessel Plates, Carbon Steel, for Moderate and Lower Temperature Service
• A 529 Structural Steel with 42,000 psi (290 MPa) Minimum Yield Point (1/2 inch
[12.7 mm] Maximum Thickness)
• A 570 Hot-Rolled Carbon Steel Sheet and Strip, Structural Quality Yield Point (1/2 inch
[12.7 mm] Maximum Thickness)

Terminology
COMPANY
Refers to PERTAMINA HULU ROKAN, as the ultimate user and owner, the authorized representative
of COMPANY or COMPANY third party inspection.

CONTRACTOR
Refers to company selected by COMPANY, which may be responsible for the detailed engineering
design, material and equipment procurement, and construction as specified in Contract, Scope of
Work, or Work Order.
Note : EPCM Company shall also be responsible as CONTRACTOR

Vendor/Sub Contractor
Refers to the company selected by COMPANY or CONTRACTOR, which is responsible for the purchase
agreement or purchase order of the goods/services specified in this specification.
Note:
• For EPC (Engineering, Procurement and Construction) project purposes: The terminology shall
have the meanings as above.
• For “Direct Procurement” by COMPANY purposes: Vendor shall also be responsible as
CONTRACTOR.

MIGAS
Indonesian Government body responsible for issuing approvals and licenses for oil and gas facilities.

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Conflicting Requirements
In case of conflict between this Specification and its associated Specifications and the above Codes
and Standards, the Vendor shall bring the matter to the COMPANY’s attention for resolution and
approval in writing. However, the most stringent requirement shall apply.

2 WPS DOCUMENT
• Welding procedure specification document, which serve as welding guidance, shall conform
and qualified with the requirement on ASME Code or AWS Code and/or Local regulations.
• Welding terms and definitions shall be in accordance with AWS A3.0.
• Welding procedures shall identify and cover all welding that will be done on the specified
project. The document shall include the following: Welding Procedure Specifications (WPS),
Procedure Qualification Test Records (PQR), ranges of variables qualified, a weld map or
description identifying which welding procedure will be used for each weld, method and
extent of inspection. For piping, representative weld maps illustrating the applicable weld
procedures are required.
• CONTRACTOR shall be responsible for reviewing of their Vendor WPS/PQR for compliance
with project specification requirements, codes and standards. Vendor WPS/PQR shall be
submitted to COMPANY for review after CONTRACTOR has been satisfied that project
specification requirements, codes and standards have been met.
• The procedures (WPS, PQR, etc.) shall have MIGAS approval.

3 WELDING PROCESS
The following welding processes may be used in the fabrication work:
• SMAW (Shielded Metal Arc Welding)
• GTAW (Gas Tungsten Arc Welding)
• SAW (Submerged Arc Welding)
• GMAW (Gas Metal Arc Welding)
• FCAW (Flux Cored Arc Welding)

4 VARIABLE
Each welding variable shall be as specified on the ASME Section IX QW 250 or as per AWS D1.1 par.
5.5 to develop welding specification procedure or welding procedure qualification.
Material
Base Metals
• The base metals may consists of either plate, pipe, or other product forms. Qualification in
plate also qualifies for pipe welding and vice versa.
• Base metals that may be welded shall be grouped as follows:
• Specified minimum yield strength less than or equal to 42,000 psi.
• Specified minimum yield strength greater than 42,000 psi but less than 65,000 psi.
• Specified minimum yield strength greater than or equal 65,000 psi.
Grouping of base metal, in accordance with specified group number (P or S), shall meet
requirement on ASME Section IX QW-420.

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• The pressure containing equipment constructed with P-No. 11 base metals, weld grooves for
thickness less than 5/8 inches (16 mm) shall be prepared by thermal processes, when such
processes are to be employed during fabrication. Back gouging, back grooving, or removal of
unsound weld metal by thermal processes shall include preparation of the above weld groove
which is to be employed during fabrication.
• For structural steel, base metal that listed in Table 3.1. AWS D1.1 shall qualify other base metal
groups in accordance with Table 4.7. AWS D1.1.

TABLE 1
FERRITE CONTENT OF AUSTENITIC STAINLESS STEEL WELD METAL

Weld PWHT or Service

Ferrite % Ferrite No.
Material Temperature

o
308, 308L Less than 800 F 5 - 15 5 - 17
316, 316L
309, 309L o
800 F and over 5-9 5 - 9.8
347

• When backing base metal is required, backing steel shall conform to the requirements
on AWS D1.1. par. 5.2.2.1 and par. 5.2.2.2.
• Dissimilar base metal thickness on groove welds shall meet requirements on the ASME
Section IX QW-202.4.
• When designated by COMPANY, the base metals to be welded shall be ordered to the
minimum impact strength (tested at a specified temperature).
• Charpy V-Notch test shall be conducted in accordance with ASTM E 23.
• Material Test Report of impact test shall be obtained from the manufacture for
all base materials, which are impact tested. Chemistry, mechanical properties,
heat treatment, and impact properties shall be reported in the material test
report. The results shall be within the limitations specifications.
• A COC (Certification of Compliance) shall be obtained from the manufacture for all non-
impact tested materials. The COC shall be made available to the COMPANY for review,
upon the requested by COMPANY.

Filler Metals
• Application of filler metal according to the type of process to be as follows:
• SAW (Submerged Arc Welding) process shall be in accordance with the requirements
of AWS A5.17. or AWS A5.23.
• SMAW (Shielded Metallic Arc Welding) process shall be in accordance with the
requirements of AWS A5.1. and AWS A5.5.
• FCAW (Flux-Cored Arc Welding) process shall be in accordance with the requirements
of AWS A5.20. or AWS A5.29 classification E70T-1 (or E71T-1) or E70T-5 (or E71T-5).
• GMAW (Gas Metallic Arc Welding) process shall be in accordance with the
requirements of AWS A5.18 classifications ER70S-2, ER70S-3, and ER70S-6 or AWS
A5.28.
• GTAW (Gas Tungsten Arc Welding) process shall be in accordance with the
requirements of AWS A.5.18 classification ER70S-2, ER70S-3, and ER70S-6, or AWS
A.5.28 and AWS A5.30.
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• Electrodes of the following classification are not permitted for pressure retaining
component or boundary welds: E6010, E6012, E6013, E6020, E7014, E7020, and
E7024 unless approved by CONTRACTOR/COMPANY.
• Filler metal for welding similar materials shall be of the same nominal analysis as the
base material, except as follows:
 AWS type 347 filler metal shall be used for welding type 321 stainless steel
material.
 AWS type 308 filler metal shall be used for welding type 304 stainless steel
material (type 308L shall be used for type 304 L).
 The following filler metals shall be used for welding 11 to 13 percent
chromium steels: AWS 410, E410Cb or E309; Inco- Weld A; Inconel 82 or 182.
For 11 to 13 percent steels in cyclic service, or for design temperatures over
660F, only Inco-Weld A, Inconel 82, or Inconel 182 are acceptable.
 For chromium-molybdenum steel, filler materials such as Inconel 82 and 182
or Inco-Weld A may be used if approved by COMPANY.
 Filler metals for welds joining dissimilar base metal materials shall be
submitted to COMPANY for approval.
• Filler metals for welds shall meet the same minimum impact test requirements as
those imposed on the base metal.
• In all welding processes, the filler wire shall contain all alloying elements and shall
meet all chemical composition requirements for the wire classification. Exceptions are
subject to COMPANY’s approval.
• Carbon steels shall not be welded with C-0.5Mo weld metal unless the weld is
postweld heat-treated and the procedure qualification record includes weld hardness
data. These data shall show that the weld and heat-affected zone hardness have not
exceeded 225 BHN (238 HV10).
• For welding carbon steel, submerged arc welding wires shall be limited to AWS
classifications ELXX and EMXXX and submerged arc welding fluxes shall be limited to
classifications F72 and F62, unless otherwise approved by COMPANY. Welding wire
classification EH14 may be used, but a hardness test survey of the weld and HAZ, is
required during procedure qualification. Hardness shall not exceed 225 HB. Recycled
flux shall not be used.
• Low-hydrogen electrodes shall be used for all shielded metal arc welding when any of
the following conditions apply :
 Valve of flange rating is Class 400 or higher.
 Base metal has a minimum specified tensile strength greater than 60,000 psi.
 Base metal has a carbon equivalent (CE) exceeding 0.43, based on weight
percent of the elements :

CE = C + Mn + Cr + Mo + V + Ni + Cu
6 5 15

 Thickness of butt welds and fillet welds (throat) exceeds 0.5 inch.
 Castings are to be weld repaired.
• For root pass welding of P-1 and P-3 steel piping materials, AWS cellulose electrode
classifications E6010/E6011or E7010- A1/E7011-A1 may be used.

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• For welding 5 through 9 percent nickel steels, the filler materials shall be reviewed
and approved by COMPANY and qualified by procedure testing in the maximum plate
thickness specified for each job.
• Filler metals and consumable inserts for austenitic stainless steel welds shall be
selected procedure weld deposits that fall within the ferrite ranges and numbers given
in Table 1 of this document . This restriction is intended to prepare. It shall be
associated with sigma-phase formation and microfissuring in fully austenitic welds.
• Filler material of E309 austenitic stainless steel or E309L, Inconel 182, or Inco-Weld A
shall be used for welding carbon or low-alloy steels to austenitic stainless steels.
• Storage and Handling
Filler metal storage and handling shall be as recommended by the filler metal manufacturer
or minimum shall be as following guidance:
• SMAW (Shielded Metal Arc Welding) Electrodes
 Low Hydrogen Electrodes (such as E7018-1; E7028; E8018- X; and E11018)
shall always be stored in unopened and undamaged factory sealed container
or electrode storage oven at 275o F (120 o C). The oven may be stationary or
portable (rod caddy).
 CONTRACTOR shall develop and implement filler metal storage and handling
procedures such that filler materials are maintained in a clean, dry condition
up to the time of use. Low hydrogen electrodes shall be handled and stored
in accordance with the manufacturer's recommendations to avoid moisture
pickup and to retain the low hydrogen characteristics of the electrode.
 CONTRACTOR shall have a welding materials handling procedure, which
specify maximum exposure limits of electrodes removed from storage.
Electrodes that are exceeding exposure limits shall be re-baked (according to
manufacturers' guidelines) prior to reuse. One re-bake cycle is permitted.
Wet, damaged, or contaminated electrodes shall be discarded.
 Electrodes shall be properly identified at all times.
• SAW Electrodes and Fluxes
 Submerged arc wire shall be stored with manufacture wrapper intact. Coils
that have been partly used shall be protected and identified before being
returned to storage. Contaminated or unidentified wire shall not be used.
 Flux used for SAW shall be dry and free from contamination. Flux shall be
stored in factory packaging until time of use. Flux from damaged packages
shall be dried at 300 oF, 149 oC, for 1 hour before use.
• GMAW (Gas Metal Arc Welding) and GTAW (Manual and Automatic Gas Tungsten Arc)
Electrodes and Gases
 Wires shall be stored with manufacture wrapper intact. Coils/ fillers that have
been partly used shall be protected and identified before being returned to
storage. Contaminated or unidentified wire shall not be used.
 Gas used for shielding shall be welding grade and have a dew point of minus
40 oF (minus 40 o C) or lower.

Position
 Limitation of weld positions during fabrication and/or qualification shall be in accordance to
Table 4.1 of AWS D.1.1 and/or as specified on ASME Section IX QW-461.9.

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Welding Procedure PHR-PP-QC-GG-006

 Special position is permitted to perform as long as meet requirement as defined on ASME

Section IX QW-461.1 and QW-46.2.

Thermal Treatment
Preheat and Interpass Temperature
 Base metal shall be preheat, to prevent cracking, to a temperature not less than the minimum
value listed on the welding procedure specification.
 Should be a preheat and interpass temperature required by welding procedure specification,
Table 3.2 AWS D1.1 shall be used as guidance.
 For combinations of base metals, the minimum preheat and interpass shall be based on the
highest value as specified on the Table 3.2 AWS D1.1.
 Decreasing or increasing temperature of preheat treatment shall accordance to the ASME
Section IX QW-406.
 Preheat treatment of each P-number of material shall accordance to the ASME/ANSI B31.1
par. 131.4.

Post Weld Heat Treatment

 Post weld heat treatment shall be carried out in enclosed furnace. The furnace atmosphere
shall controlled to avoid excessive oxidation of the surface of the component during the
heating and holding period/time.
 Heat treatment may be accomplished by a suitable heating method, which will provide the
desired heating and cooling rates, the required metal temperature, temperature uniformity
and temperature control. This treatment shall accordance to ASME Section IX QW-407 and
ASME/ANSI Table 132 for pressurizes component/equipment, and AWS D1.1 par. 5.8 for
general structural steel.
 Direct flame impingement by torch or furnace burner during PWHT is not permitted.
 The maximum Brinell hardness of weldments (weld deposits and heat- affected zones) in all
steels after heat treatment shall be 215 BHN. If welds are furnace heat treated, a minimum of
10 percent shall be tested to verify that the hardness criterion has been met. If local heat
treatment has been applied, each weld shall be tested. Welds in critical service such as amine,
wet hydrogen sulfide, and hydrogen fluoride shall also not exceed a maximum hardness in the
deposited weld metal of 200 BHN.
 Any welding treatment after PWHT is prohibited.
 If internal parts are installed before the heat treatment, all parts shall be realigned after heat
treatment.
 Post weld heat treatment is not required for the following conditions:
• weld in non-ferrous metal
• welds exempted in ASME/ANSI B31.1 Table 132
• welds subjected to temperatures above the lower critical temperature as specified in
ASME/ANSI B31.1 Table 129.3.2 during fabrication or any specified in ASME/ANSI
B31.1 par 132.1.
• when the stress relieving of weldments of A514, A517, A709 Grades 100 and 100W,
and A710 as specified in AWS D1.1.
• Exemptions listed in ASME/ANSI B31.3 “Requirements for heat Treatment”

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Welding Procedure PHR-PP-QC-GG-006

5 FABRICATION
Surface Preparation
• Surfaces will be welded shall be cleaned and free from paint, oil, dirt, scale, oxides, and other
foreign material detrimental to welding for at least 1 inch (25 mm) from joint preparation
(internally and externally).
• Flux, weld spatter, and slag shall be removed from weld beads by chipping, grinding, or both,
and wire brushing before starting to deposit a succeeding pass.

Joint Requirement and Preparation

• Permanent backup rings are not permitted without specific written authorization from
COMPANY.
• Non-pressure retaining components, except those fabricated from carbon steel (P - No.1), or
those specifically exempted by COMPANY shall be made with a root- back purge. Double -
welded butt joints, joints with backing rings, and fillet welds are exempt from purge gas
requirements. Purge gas shall follow the requirements listed below as a minimum:
• Welding grade argon inert gas shall be used as the root purging gas. The use of
nitrogen for a purge gas is not permitted.
• While GTAW is to be used for a minimum of 2 weld layers, root shielding shall be
continued until the root and such additional passes as may be required to bring the
deposited weld metal thickness up to 3/16 of an inch (minimum) have been
deposited. Should obtain 100% purge throughout welding operation, minimum 5
liters/minute.
• The materials used for pipe purging dams and the methods employed in their
placement, use, and subsequent removal shall be as required to ensure that no
damage results to the piping or related components.
• The purge gas shall be verified to contain less than 1 percent oxygen (measured by an
oxygen analyzer), or flow for a sufficient amount of time to allow at least 6 purge
volume changes, prior to the initiation of welding.
• Welding edge preparations (bevels) shall be suitable for the welding process to be
used. For pressure-containing welds, the contour shall permit complete fusion
throughout the joint. Bevels shall conform substantially to those used in the
procedure qualification.
• All weld bevels and weld surfaces shall be free from cracks, porosity, slag inclusions,
and other defects indicative of poor manufacture.
• Weld edge preparations shall be made by machining, grinding, or thermal cutting, and
the surfaces shall be reasonably smooth and true. Materials that require preheat for
welding shall be preheated in the same manner for thermal cutting or gouging.
• Weld bevel preparation for carbon steel over 4 inch thickness, quenched, and
tempered carbon steels, HSLA steels, and steels containing more than 0.5 percent
chromium shall be machined, or ground back to clean and sound metal if they are
flame or arc cut. At least 1/16 inch of metal shall be removed.
• All surfaces to be welded shall be clean and free from paint, oil, dirt, scale, oxides, and
other contaminants detrimental to welding. Cleaning shall be performed in a manner
that will not lead to additional contamination of the weld or adjoining base metal.
• Only stainless steel brushes and tools shall be used on stainless steel and nickel-
alloyed materials.
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Welding Procedure PHR-PP-QC-GG-006

• Grinding disks containing sulfur (iron sulfide) shall not be used on 5 through 9 percent
nickel steels, stainless and alloy steel, or nonferrous materials.
• Cleanliness shall be maintained after completion of welding. All stubs, rods, flux, slag,
and foreign material shall be removed from the vicinity of the equipment or piping.
• Full inspection shall be applied during welding operation of stainless steels or any
obvious discoloration in to extreme heat inputs. In that case, the operation the
specific workstation shall cease until further an investigation.

Workmanship
• The weld preparations shall be aligned as accurately as is practical, and alignment shall be
preserved during welding. In all cases, weld joint alignment shall be sufficient to produce
welds meeting the requirements of this specification.
• Surfaces and edges to be welded shall be smooth, uniform, and free from fins, tears, cracks,
or other defects, which would adversely affect the quality or strength of the weld.
• Tack welds shall be preheated as required for the final weld. Tack welds that are to be
incorporated into the final weld shall have a profile, which can be welded over without
adversely affecting the weld quality.
• Tack welds, which are not incorporated into the welds, shall be removed completely after
their need has been fulfilled.
• Tack welds shall be made by qualified welders, using a qualified procedure comparable to
those used for the component weld.
• Temporary attachments such as hold-down fixtures or alignment bars shall be removed; the
surface under such welds shall be properly conditioned to eliminate surface stress risers. The
attachment material shall be of the same chemical composition as the base material.
• Arc strikes made in areas not to be covered by the finished weld shall be ground and visually
inspected to ensure that the pipe surface is restored to its original condition (apply NDT
method).
• Weld slag, scale, cracked welds, surface porosity, or gross irregularities shall be removed
before welding resumes. Weld craters shall be completely filled before depositing subsequent
weld beads.
• The use of pneumatic cleaning tools is acceptable and is not considered as peening.
• Grinding wheels, rotary burrs, and austenitic stainless steel wire brushes, used on austenitic
stainless steel or other high nickel and nonferrous alloys, shall not have been used previously
on ferrous materials. Metal removal and abrasive tools used on galvanized material shall be
segregated from other materials.
• As welded surfaces are permitted, however, the surfaces of welds shall be sufficiently free
from coarse ripples, grooves, overlaps, abrupt ridges, and valleys to allow the proper
interpretation of radiographic and other NDEs when NDEs are required. When an as-welded
surface interferes with an examination, the surface shall be ground to permit the proper
interpretation of the examination.
• Weld metal shall be deposited for the full thickness of the joint preparation, regardless of
minimum wall thickness. Underfill shall not be permitted.

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6 INSPECTION AND TEST

General
• Welds that are deposited by procedures differing from those properly qualified and approved
shall be rejected and completely removed.
• Cleanliness shall be maintained after completion of welding. Stubs, rods, flux slag, or other
foreign material shall be removed from inside and outside surfaces of the weldment.
• Welds burned, oxidized during welding, of improper size, or otherwise defective shall be
removed from the component or equipment and rewelded according to Section 8 of this
procedure.
• COMPANY may require additional NDE beyond that specified in the contract requirements, at
its discretion. Where the results of such additional NDE indicates that the weldment meets
the applicable requirements, the cost of the additional NDE shall be at COMPANY expense.
Where additional NDE reveals the presence of rejectable discontinuities, the cost of the
additional NDE, together with the cost of repairs and additional post repair NDE, shall be at
the CONTRACTOR’s expense.
• COMPANY’s Inspector or an authorized representative shall have free access to
CONTRACTOR's work place and shall have the right of rejection of workmanship that does not
meet this specification. At the direction of the Inspector, additional testing of welds shall be
done if the Inspector deems it essential to maintain quality.
• COMPANY’s Inspector has the option of selecting locations for any spot or random NDE.
• Inspections and NDEs shall be performed as specified and as a minimum, NDE requirements
shall be as specified in the applicable governing code or standard.
• NDE techniques, records, acceptance criteria, and additional general requirements shall be in
accordance with test plans developed by CONTRACTOR and approved by COMPANY. NDEs,
except visual examination, shall be performed by personnel certified in accordance with ASNT
recommended practice SNT-TC-1A. Other types of certification require written authorization
by COMPANY. NDE procedures shall be submitted to COMPANY for approval before
examination. Other records, if requested, pertaining to inspection shall be made available to
COMPANY’s Inspector.
• The performance of supplemental testing shall be conducted as required by local regulations.

NDE (Nondestructive Examination) Requirements

The extent of nondestructive examination requirements for each piping line class is to be specified
and submitted to COMPANY for review and approval.

Visual Examination
Visual examination and evaluation of indications shall be in accordance with ASME Code, Section V,
Article 9, and ASME B31.1 Paragraph 136.4.2 or B31.3 Paragraph 344.2; whichever is applicable.

Liquid Penetrant Examination

• Liquid penetrant examination and evaluation of indications shall be in accordance with the
requirements and methods specified in ASME Code Section V, Article 6, and ASME B31.3
Paragraph 344.4 or B31.1 Paragraph 136.4.4.A; whichever is applicable.
• Penetrant materials shall meet the requirements of Paragraph T-625 of Article 5, Section V of
ASME Code, for sulfur and halogen content, regardless of the type of material to be examined.

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• Liquid penetrant examination of weld shall include a band of base metal at least 25 mm wide
on each side of the weld.
• Except for piping, liquid penetrant shall be used only for nonmagnetic materials and through
9 percent nickel steels.
• Cleaning and developing solutions with a combined total residual sulfur and halogen content
of one percent by weight or greater shall not be used.

Magnetic Particle Examination

• Magnetic particle examination and evaluation of indications shall be in accordance with the
requirements and methods specified in ASME Code, Section V, Article 7, and ASME B31.1
Paragraph 136.4.3.A or B31.3 Paragraph 344.3; whichever is applicable.
• Magnetic particle examination of welds shall be included a band of base metal at least 25 mm
on each side of the weld; the magnetic yoke method shall be used.
TABLE 2

WELD EXAMINATION PROCEDURES AND ACCEPTANCE STANDARDS

Standard
Method (ASME Code, Section VII)

Radiography:
- Complete Paragraph UW 51
- Spot / Random Paragraph UW 52
Magnetic Particle Appendix 6
Liquid Penetrant Appendix 8
Ultrasonic Appendix 12

Ultrasonic Examination
Ultrasonic examination and evaluation of indications shall be in accordance with the requirements
and methods specified in ASME Code Section V Article 5, and ASME B31.1 Paragraph 136.4.6B or B31.3
Paragraph 344.6; whichever is applicable.

Radiographic Examination
• Radiographic examination procedures, techniques, and evaluation of indications shall be in
accordance with ASME Code Section V Article 2 and ASME B31.1 Paragraph 136.4.5 or B31.3
Paragraph 344.5; whichever is applicable.
• Additional requirements for radiographic examination shall be as follows:
• Type 1 film (fine grain) shall be used unless approved by COMPANY.
• Lead screens shall be used.
• Approval from COMPANY is required to use of penetrameters other than those
specified in the applicable Code.
• Whenever 5% radiography is specified, the following rule shall be applied, at least 5% of the
number of welds within the specified material group or line class shall be 100% radiograph
around their total circumference.

Mechanical Testing of Welding

Mechanical tests shall be conducted as required by ASME B31.1 or B31.3, ASME Section IX and AWS
D1.1; whichever is applicable. COMPANY shall have the option to witness the mechanical testing as

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Welding Procedure PHR-PP-QC-GG-006

specified. Method of mechanical testing such as, Charpy Impact Testing, Brinell Hardness Testing,
Ferrite Testing, Tensile Testing, Guided Bend Testing, Fillet Weld Testing, Stud Weld Testing and Butt
Weld Testing.

7 REJECTION
• The welding result shall be rejected when can not meet the acceptance criteria of each non
destructive examinations and mechanical testing as specified on the applicable code or any
modification of COMPANY specification.
• Visually the welding result must not indicate one of the following :
• Weld size and length (for drawing conformance). Suitable gages shall be used.
• Cracks. (No cracks shall be present.)
• Weld shape and appearance.
• Craters (to be filled to the full cross section of the required weld).
• Undercut (within the requirements specified herein).
• Overlap or lack of fusion (none present in accordance with this Specification).
• Surface porosity and inclusions. (The diameter of surface porosity or inclusions shall
not exceed 3/32 of an inch, nor shall there be a frequency greater than one in 4
inches of weld length.)
• Weld spatter and slag. (All weld spatter and slag shall be removed in a manner to
provide a surface finish conforming to the requirements of the base material
specification.)
• Arc strikes. (All indications of arc strikes shall be removed.)

8 WELDING REPAIRS
Welds that do not comply with the specified acceptance criteria shall be repaired and re-examined
in accordance with the following:
• The defect area shall be excavated and examined to ensure complete removal of defects. The
repaired areas shall be re-examined using the same inspection procedures by which the defect
was originally detected.
• Repairs to correct weld defects shall be made using the same procedure used for the original
weld or other previously approved weld procedures. Further attempts shall be approved by
COMPANY.
• Defects that are outside the acceptable limits of the codes, project specifications, or other
requirements stated on the purchase order shall be cause for rejection. The CONTRACTOR or
Vendor shall be responsible for the remedial action as is necessary to secure acceptance.
• Repairs of major defects and all repairs in plate or forging require prior approval by COMPANY.
Repairs of weld defects are considered major when the cavity after defect removal exceeds
one-half the wall thickness or 1/2 inch (1 inch for castings), whichever is smaller, or when the
defect resulted in leakage during a hydrostatic test. The repair procedure shall be in writing
and shall include information on methods used for defect removal, inspection of cavity,
welding procedures, and details of nondestructive examination of the repaired area.
• All welds (including weld overlays) that are found by inspection to be unsound, or that are
deposited by procedures differing from those properly qualified, shall be rejected. They shall

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be completely removed from the equipment and replaced in accordance with approved
procedure or shall be repaired subject to COMPANY's approval.
• Repair of local cavities in overlay welds that penetrate the base metal by more than 10 percent
or 3/16 inch, whichever is smaller, shall include having the base metal rewelded. The welding
procedure and materials used shall be compatible with the original base metal.
• Removal of defects by chipping, grinding, or gouging shall be done in such a manner as to
avoid reducing the adjacent base material thickness. If the material thickness is reduced, it
shall be restored. Complete removal of defects shall be verified by nondestructive
examination before repair is started. Repair welding shall be performed only by qualified
welders using qualified procedures.

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